3D printing becoming 'standard practice' in orthopedics

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Patient-specific orthopedic care is becoming more commonplace as 3D printing technology becomes more sophisticated and widespread, Michael Rivlin, MD, said.

Dr. Rivlin, co-founder and president of Dimension Ortho and hand surgeon at Philadelphia-based Rothman Orthopaedics, discussed the state of personalized orthopedic care and what's ahead.

Note: Responses were lightly edited for clarity.

Question: How will personalized medicine such as 3D printing benefit hand and upper extremity surgeons both in the OR and in bracing/sprints?

Dr. Michael Rivlin: 3D printing has been around for decades; however, it is recent that the application of this technology started impacting everyday patient care. From patient-specific implants to well-fitting orthotics and prosthetics, 3D printed devices are starting to become standard practice. Personalized medicine, including innovations like 3D printing, offers significant advantages for hand and upper extremity surgeons, both in the operating room and in post-operative care. 

In the operating room, 3D printing enables the creation of patient-specific surgical guides making some challenging procedures more precise, implants that are better fit for complex anatomy and anatomical models for better surgical planning. 

In the postoperative period and during rehabilitation 3D printing allows for the fabrication of custom-fit orthotic devices (braces, splints and casts) that provide superior comfort, functionality and aesthetic appeal. This level of personalization promotes better patient compliance, faster recovery, and improved overall outcomes, revolutionizing the standard of care in hand and upper extremity surgery.

Q: Can you dive into any cost-saving advantages 3D printing has to offer?

MR: We are used to smart devices. It is no longer a luxury to upgrade from a flip phone to a smartphone. With 3D braces we are following the same pattern. Custom surgical tools and anatomical models created through 3D printing can shorten surgical procedures by improving precision and preoperative planning, reducing operating room time — a significant cost factor in healthcare. Patient-specific splints and braces produced with 3D printing lower costs by minimizing the need for trial-and-error adjustments, enhancing efficiency while improving patient satisfaction. Over time, these savings contribute to more accessible, cost-effective care without compromising quality.

Q: What other orthopedic surgical trends and technologies are exciting you this year?

MR: Artificial intelligence will likely continue to improve healthcare delivery at all levels. In orthopaedics specifically, it may really shine by enhancing precision, efficiency, and patient outcomes. Better surgical predictions and planning by using 3D anatomical models; robotic-assisted systems powered by AI improve surgical accuracy and aid the surgeons. 

Additionally, AI driven processes could help optimize rehabilitation plans by analyzing patient data to forecast recovery, promoting faster and more effective healing. 

Q: Are you involved in any interesting research with Rothman this year? Can you share any unique findings?

MR: Research and improving clinical outcomes are always a focus for us at Rothman. As we continue to look for more effective and innovative ways to care for our patients, we are unique in using 3D scanning technology for injuries to help guide rehab protocols and investigating how swelling at different timepoints after upper extremity injuries predict success in rehabilitation. We can really pinpoint how the healing body part remodels and heals from injury.

Q: How are you approaching headwinds with reimbursements and payer negotiations in 2025?

MR: In 2025, we, physicians and healthcare providers, may face growing pressure to demonstrate improved patient outcomes and reduce overall healthcare costs as payers prioritize outcome-based reimbursement models. Fortunately, practicing evidence-based medicine and focusing on outcomes at Rothman Orthopaedics, we are in a great position to continue to advocate to get the best care for our patients.

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